U.S. patent application number 14/081565 was filed with the patent office on 2014-03-20 for apparatus, systems, and methods to address evaporative cooling and wet compression for engine thermal management.
This patent application is currently assigned to Cummins Power Generation IP, Inc.. The applicant listed for this patent is Cummins Power Generation IP, Inc.. Invention is credited to John R. Pendray.
Application Number | 20140076272 14/081565 |
Document ID | / |
Family ID | 43379361 |
Filed Date | 2014-03-20 |
United States Patent
Application |
20140076272 |
Kind Code |
A1 |
Pendray; John R. |
March 20, 2014 |
APPARATUS, SYSTEMS, AND METHODS TO ADDRESS EVAPORATIVE COOLING AND
WET COMPRESSION FOR ENGINE THERMAL MANAGEMENT
Abstract
An apparatus including a reciprocating internal combustion
engine with at least one piston and cylinder set and an intake
stream; at least one liquid atomizer in fluid communication with
the intake stream operable to provide a plurality of liquid
droplets with a diameter less than 5 .mu.m to the intake stream;
and a controller where the controller is able to adjust an index of
compression for the engine by: calculating a wet compression level
in response to an engine operating limit and adjusting the at least
one liquid atomizer in response to the wet compression level.
Inventors: |
Pendray; John R.; (Blaine,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cummins Power Generation IP, Inc. |
Minneapolis |
MN |
US |
|
|
Assignee: |
Cummins Power Generation IP,
Inc.
Minneapolis
MN
|
Family ID: |
43379361 |
Appl. No.: |
14/081565 |
Filed: |
November 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12825516 |
Jun 29, 2010 |
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14081565 |
|
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61269844 |
Jun 30, 2009 |
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Current U.S.
Class: |
123/25C |
Current CPC
Class: |
F02M 25/028 20130101;
F02B 47/08 20130101; F02M 26/35 20160201; Y02T 10/12 20130101; F02M
25/0227 20130101; F02M 25/0228 20130101; F02B 1/12 20130101; F02B
29/0481 20130101; F02M 25/0222 20130101; F01B 1/12 20130101; F02M
25/0225 20130101; F02M 27/04 20130101; F02M 27/08 20130101; Y02T
10/146 20130101; F02M 35/088 20130101; F02D 41/0025 20130101; F02B
47/02 20130101 |
Class at
Publication: |
123/25.C |
International
Class: |
F02B 47/02 20060101
F02B047/02 |
Claims
1-25. (canceled)
26. An apparatus comprising: an internal combustion engine with at
least one piston and at least one cylinder and an intake stream;
one or more liquid atomizers in fluid communication with the intake
stream structured to provide a plurality of liquid droplets with a
mean diameter less than 30 .mu.m to the intake stream; a controller
structured to calculate a wet compression level based on a reading
from a NOx sensor and an engine operating limit, wherein the wet
compression level is effective to reduce NOx in an exhaust stream
from the at least one cylinder; and wherein the one or more liquid
atomizers are responsive to the controller to adjust the wet
compression level to reduce NOx in the exhaust stream.
27. The apparatus of claim 26, further including at least one
liquid droplet separator in fluid communication with the intake
stream positioned downstream from the at least one of the liquid
atomizers and upstream from the engine.
28. The apparatus of claim 26, wherein the one or more liquid
atomizers include means for providing a majority of the liquid
droplets have a maximum diameter of less than 5 .mu.m.
29. The apparatus of claim 26, wherein the one or more liquid
atomizers include means for providing a majority of the liquid
droplets have a maximum diameter of less than 2.7 .mu.m.
30. The apparatus of claim 26, further comprising: means for
selecting a liquid injection location; means for selecting a liquid
injection amount; and means for selecting a liquid injection
timing.
31. The apparatus of claim 26, further comprising: a closed water
source in fluid communication with at least one of the liquid
atomizers.
32. The apparatus of claim 26, wherein the engine operating limit
includes a pre-ignition temperature threshold and further
comprising means for determining the pre-ignition temperature
threshold as a function of one or more engine knock detector
readings.
33. The apparatus of claim 26, wherein the wet compression level
corresponds to an amount of liquid determined to provide a
transition to a dry compression state after the amount of the
liquid fully evaporates.
34. The apparatus of claim 26, further comprising a plurality of
liquid droplet injectors, a plurality of liquid droplet separators
and a plurality of piston and cylinder sets; wherein the liquid
droplet injectors and the liquid droplet separators are provided
for each of the plurality of piston and cylinder sets; and wherein
each of the plurality of liquid droplet injectors and each of the
plurality of liquid droplet separators are in close proximity to
each of the plurality of piston and cylinder sets.
35. The apparatus of claim 26, wherein the controller is structured
to determine the engine operating limit in response to a set of
auto-ignition conditions and to calculate the wet compression level
based on a set of engine cycle conditions changing with an engine
cycle.
36. The apparatus of claim 26, wherein the at least one of the
liquid atomizers includes means for providing at least one of:
ultrasonic atomization, electrostatic atomization, and flash
atomization.
37. A method comprising: operating a reciprocating internal
combustion engine with at least one piston and cylinder set and an
air intake stream; generating a plurality of liquid droplets having
a mean diameter less than 30 .mu.m; providing the plurality of
liquid droplets to the air intake stream of the engine; and
controlling wet compression of the engine to reduce NOx in an
exhaust stream based on a reading from a NOx sensor by selecting at
least one of a liquid injection amount and a liquid injection
timing.
38. The method of claim 37, wherein providing the plurality of
liquid droplets in the air intake stream to the engine includes
injecting the plurality of liquid droplets into the air intake
stream according to a liquid droplet injector sequence.
39. The method of claim 37, wherein a majority of the liquid
droplets have a maximum diameter of less than 5 .mu.m.
40. The method of claim 37, wherein a majority of the liquid
droplets have a maximum diameter of less than 2.7 .mu.m.
41. The method of claim 37, further comprising: atomizing liquid to
provide the plurality of liquid droplets.
42. The method of claim 41, wherein the atomizing of the liquid
includes at least one of: ultrasonic atomization, electrostatic
atomization, and flash atomization.
43. The method of claim 37, which includes separating the plurality
of liquid droplets from larger liquid droplets.
44. The method of claim 37, wherein the controlling is performed as
a function of one or more engine operating conditions and includes
regulating a wet compression level.
45. The method of claim 44, wherein the wet compression level
corresponds to an amount of liquid determined to fully vaporize
throughout compression of the intake stream in the at least one
piston and cylinder set.
46. An apparatus comprising: an internal combustion engine with at
least one reciprocating piston and at least one cylinder and an
intake stream; means for atomizing a coolant in fluid communication
with the intake stream operable to provide a plurality of coolant
particles with a maximum diameter less than 30 .mu.m to the intake
stream; a controller configured to adjust an index of compression
for the engine by: detecting a NOx level of the engine; calculating
a wet compression level in response to the NOx level of the engine
exceeding a NOx threshold; and adjusting a coolant atomization
control schedule for the at least one atomizer means in response to
the wet compression level.
47. The apparatus of claim 46, wherein the controller is further
configured to: determine an injection amount of coolant particles
when the injection amount of coolant particles are provided on a
continuous basis; and determine a duration for providing the
injection amount of coolant particles when the at least one means
for atomizing a coolant is capable of providing the injection
amount of coolant particles to the intake stream.
48. The apparatus of claim 46, wherein the at least one
reciprocating piston and cylinder at least partially include an
insulating material.
49. The apparatus of claim 46, wherein the wet compression level
corresponds to an amount of liquid determined to fully vaporize
throughout compression of the intake stream in the at least one
cylinder.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 12/825,516, filed on Jun. 29, 2010, which
claims the benefit of U.S. Provisional Patent Application No.
61/269,844 filed Jun. 30, 2009, both of which are hereby
incorporated by reference in their entirety.
BACKGROUND
[0002] The present application relates to thermal management of an
internal combustion engine, and more particularly, but not
exclusively to evaporative cooling and wet compression of an
internal combustion engine.
[0003] Engine knocking (also called detonation or spark knock and
pinging) occurs in internal combustion engines when a portion of
the air/fuel mixture in the cylinder does not combust with the rest
of the air/fuel mixture in the cylinder at the precise time in the
piston's stroke cycle as determined by the engine control system.
The peripheral explosions create shock waves that can be heard by
the operator. The effects of the engine knock shock waves can be of
no consequence or catastrophic to the engine. In between these
extremes, engine knock limits the compression ratio, ignition
timing, and other engine operating parameters that effect
efficiency on reciprocating internal combustion engines. Without
engine knock, these parameters could be changed to enable more
efficient operation and generally re-optimize the engine for
superior performance.
[0004] Liquids can be used to cool combustion gases in internal
combustion engines. The term wet compression refers to the act of
vaporizing liquid during compression. The phase change from liquid
to vapor consumes relatively large amounts of energy with a
relatively small temperature change. Wet compression therefore
allows a thermodynamic cycle that efficiently compresses an
air/liquid mixture with a lower temperature increase than
compressing dry air, enabling higher compression ratio and peak
pressure at a constant peak temperature.
[0005] Humid air and water injection are related processes that
provide some benefits to reciprocating internal combustion engines.
Humid air cycles have been used in reciprocating engines and gas
turbines to reduce NOx emissions. Water injection was used in WWII
to increase aircraft engine power density, primarily for takeoff,
but there are differences that allow wet compression to improve
power density and efficiency relative to humid air and water
injection.
[0006] Wet compression may be confused with humid air thermodynamic
cycles. Humid air cycles inject steam or other non-reactive vapor
into the air/fuel stream. Vapor injection increases the thermal
mass of the air/fuel mixture and dilutes the charge air. The
dilution decreases the tendency to knock while maintaining
stoichiometric combustion. The larger thermal mass reduces the peak
temperatures in the combustion chamber therefore reducing NOx
formation.
[0007] Because humid air is already in vapor phase when mixed with
the air/fuel stream, it cannot go through a phase change during
compression. When humid air is compressed, the temperature
increases almost as fast as if the air were dry. The temperature
rise is slightly lower since the specific heat ratio of the vapor,
e.g. water, is often lower than the specific heat ratio of the
air/fuel mixture. Any improved knock margin is primarily dependant
upon the dilution effect.
[0008] In water injection, large liquid droplets are added to an
air/fuel stream to provide cooling from the phase change during
compression and combustion. Upon injection, water droplets may
follow one of two paths: collision with internal surfaces or
entrainment in the airflow.
[0009] Large water droplets may collide with internal surfaces
during airflow direction changes. The inertia of large water
droplets can overwhelm the friction from surrounding airflow and
hinder the droplet's ability to follow airflow changes around
structures within the air ducting, intake manifold, and cylinder,
causing droplet collisions with internal surfaces. If the surface
is hot, such as in the cylinder, the liquid may vaporize, thus
making the system act similar to humid air injection. If the
droplet does not vaporize, it is pushed by the airflow along the
internal surface. As it is moving, the liquid may coalesce with
other liquid droplets. The ratio of surface area to volume
decreases, which reduces the effects of air temperature on liquid
vaporization. Surface wetting may also lead to engine corrosion
issues such as cylinder liner scuffing and oil quality
degradation.
[0010] If the droplets do not collide with a solid surface, they
may remain in the airflow. Eventually, at least some of the
droplets may arrive in the cylinder. During compression, the air
temperature surrounding the droplets increases. Increased
temperature causes heat to flow from the air to the water droplet.
As the thermal gradient between the droplet and surrounding air
increases, the heat transfer rate increases. Heat transfer across
the large thermal gradients associated with large droplets
increases system entropy, however, thus reducing cycle
efficiency.
[0011] Sufficiently large droplets have enough thermal inertia to
remain in liquid form during combustion. Large droplets have a
lower surface area to volume ratio than small droplets. Because
heat transfer depends upon surface area and heat required for total
vaporization depends upon volume, large droplets may not have
enough time to completely vaporize. When the large droplets are
present during combustion, they lower peak cylinder pressures and
temperatures and slow flame propagation which decreases system
efficiency.
[0012] While water injection and humid air injection may have some
ability to reduce engine knock, various shortcomings persist:
entropy produced from large thermal gradients required during
liquid vaporization; corrosion from surface wetting; and cooling
the combustion process. Humid air cycles have temperature increases
during compression equivalent to dry air compression limiting the
efficiency of the combustion system. Thus, there is an ongoing
demand for further contributions in this technical arena.
SUMMARY
[0013] One embodiment of the present invention is a unique engine
thermal management system. Other embodiments include unique
methods, systems, devices and apparatus involving managing intake
air cooling, compression inter-cooling and/or wet combustion with
an engine thermal management system. Further embodiments, forms,
features, objects, aspects, benefits, and advantages of the present
invention shall become apparent from the figures and descriptions
provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic diagram of a system with an engine
relating to one embodiment.
[0015] FIG. 2 is a schematic diagram of a system with an engine
relating to another embodiment.
[0016] FIG. 3 is a schematic diagram of a system with an engine
relating to yet another embodiment.
[0017] FIG. 4 is a diagram illustrating an exemplary controller for
engine thermal management.
DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS
[0018] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is intended. Any
alterations and further modifications in the described embodiments,
and any further applications of the principles of the invention as
described herein are contemplated as would normally occur to one
skilled in the art to which the invention relates.
[0019] One embodiment of the present application includes an
apparatus and method for a reciprocating internal combustion engine
for altering the isentropic or polytropic index of compression by
adding a non-gas matter with a sufficiently large surface area to
maintain a low thermal gradient during the phase changes throughout
intake and compression strokes. One specific example of this
embodiment is the addition of fine water droplets (<5 micron) to
the intake air stream where the droplets act as an intercooler
during the compression stroke, reducing peak charge air
temperature, and thus reducing the tendency for the engine to
knock.
[0020] Wet compression is an engine conditioning process which
utilizes droplets that behave as though they are integral parts of
the intake air while remaining in liquid form. For example, the
droplets cool a majority of the intake air uniformly to avoid hot
spots. For wet compression conditions during air intake, smaller
droplets may contribute to improved dispersion in the charge air.
For a similar volume of liquid, the separation between droplets is
less with smaller diameter droplets, and correspondingly provides
more cooling points and keeps the bulk temperature closer to a
saturation temperature. When small droplets avoid contact with
surfaces and substantially vaporize before the combustion process
begins, the efficiency of the system should increase. These
conditions may be met if the droplets are sufficiently small.
[0021] In another embodiment, entrained droplets in the intake air
improve the volumetric efficiency of a reciprocating internal
combustion engine. Under normal conditions as reciprocating
internal combustion engines draw air into the cylinder, the fresh
air mixes with residual exhaust and typically is heated by the
cylinder walls, piston, and head. This heating causes the gas to
expand, thus reducing the amount of air introduced to the cylinder
in each cycle. Under wet compression conditions, the entrained
droplets keep the charge air cool, which increases the charge air
density which may contribute to increased power density.
[0022] Unfortunately, introducing liquid to the compression stage
of an engine may increase system entropy. Heat flows from the
compressing air to the liquid to force the liquid droplets to
vaporize. This heat transfer is driven by a thermal gradient. Heat
transfer across a thermal gradient increases entropy, and the
larger the thermal gradient, the more entropy is produced. In one
embodiment a condition for liquid introduction to the compression
stage is a significant amount of liquid surface area therefore
there is a reduced thermal gradient utilized for the heat transfer.
Liquid droplet diameter reductions generally increase the surface
area for a given amount of liquid. The reduced thermal gradient of
the reduced diameter liquid droplets may provide a reduced entropy
level and result in improved efficiency of the combustion
system.
[0023] Liquid that is present beyond the intake and compression
stages and continues into the combustion stage may have ill
effects. The thermal gradient tends to be large for the heat
transfer, since the combustion temperature is hot while the liquid
is still at its saturation temperature. Combustion temperatures may
remain high before vaporizing the water, allowing elevated NOx
formation. If a similar amount of water were vaporized before
combustion, it may improve NOx emissions and efficiency.
[0024] Further, when droplets carry into the combustion stage, the
phase transformation tends to cool the combustion process. Wet
combustion may decrease system efficiency due to a lower
temperature and therefore a decreased pressure rise compared to dry
combustion, as well as slower flame propagation. Systems designed
for intake air cooling or inter-cooling with wet compression may
find it advantageous to avoid operations that may create wet
combustion conditions.
[0025] Understanding the parameters that affect droplet
vaporization contributes to wet compression optimization. The
energy consumed during liquid vaporization drives the inter-cooling
effects of wet compression. Droplet diameter is one parameter for
vaporization properties. For a given quantity of water for one
embodiment, the time required for droplet vaporization is partially
dependant upon the diameter of the droplet squared. At a constant
thermal gradient relative to the bulk gas temperature, the time to
vaporize a liquid droplet scales approximately quadratically with
the droplet diameter. With a similar thermal gradient, a 5 .mu.m
droplet will likely vaporize in approximately 1/16.sup.th the time
of a 20 .mu.m droplet and a 1 .mu.m droplet will likely vaporize in
approximately 1/400.sup.th the time because of the surface to
volume ratio and dispersion effects of smaller droplets.
[0026] In one embodiment, the average droplet diameter is less than
10 microns. In another embodiment, droplet diameter is equal to or
less than 5 microns for droplets comprised of water. In yet another
embodiment, it was surprisingly discovered that a desirable
inter-cooling effect may be achieved by keeping the maximum
diameter of each droplet to less than 2.7 microns in a 1200 RPM
engine with the droplets comprised of water.
[0027] Water injection generally uses large droplets of water, 20
.mu.m to over 100 .mu.m, and is intended to cool the combustion by
vaporization and air/fuel dilution. Large droplets may provide
limited cooling during the compression stroke. In contrast to one
embodiment of the present application, wet compression uses small
droplets, 1 .mu.m or less to 5 .mu.m, to allow faster vaporization,
acting as an inter-cooler for the compression stroke and more fully
vaporizing before combustion. Small droplets generally are able to
more fully vaporize before combustion and contribute to reduced
entropy production during vaporization. While the inter-cooling
effect may be more efficient, the effect may also utilize less
water to provide a similar knock margin and NOx reduction. Less
water is utilized since inter-cooling contributes to reduced
compression work, therefore requiring less energy dissipation.
[0028] It should be appreciated that the fast vaporization rate of
small droplets tends to reduce corrosion and oil-loss sometimes
associated with water injection. Small droplets can potentially
vaporize in less than a millisecond when exposed to large thermal
gradients. Thus if a small droplet is on a trajectory toward the
cylinder wall, the heat from the cylinder will likely vaporize the
droplet before it is able to contact a cylinder surface. A larger
droplet would take longer to vaporize, and may enable liquid-solid
contact. It should be appreciated that small diameter liquid
droplets are better able to follow airflows effectively as compared
to large vapor droplets, thus making port injection schemes
possible as an alternative to direct injection.
[0029] Typically, it is desired that droplets follow airflow to
avoid wetting internal surfaces. Larger droplets, common to water
injection systems, are more likely to collide with engine surfaces.
Surface wetting decreases compression inter-cooling effectiveness
and may cause corrosion issues. Droplets that collide with internal
surfaces decrease their ratio of surface area to volume, which
reduces the positive effects of wet compression. Liquids on
internal surfaces may also become a source for possible corrosion
or lubricant removal. As the surface area to volume ratio of the
droplets increases, so does the droplet trajectory's dependence
upon the surrounding airflow.
[0030] As the droplet temperature increases from heat flow, the
droplet reaches its saturation temperature and vaporizes. The heat
used to create this vaporization would otherwise be used to
increase the temperature of the compressing air, thus droplet
vaporization may effectively reduce compression temperature,
suppressing knock. During compression the pressure also increases,
thus the saturation temperature increases throughout the
compression stroke. Vaporization adds to the total number of gas
molecules in the compression chamber, thus it also adds to the
total chamber pressure. This allows the isentropic or polytropic
index of compression for temperature to be lower than the effective
isentropic or polytropic index of compression for pressure.
[0031] Entrainment and vaporization rate requirements suggest
small, uniform water droplets. Creating micron diameter droplets is
difficult for injectors using air or water pressure for
atomization. One embodiment includes a technology that can create
droplets that are small and uniform which is referred to as
ultrasonic atomization. Ultrasonic atomizers can produce water
droplets with diameters lower than 1 .mu.m. Ultrasonic atomizers
effectively create microscopic waves that spray water into the air
stream. Droplet size depends upon driving frequency, which can be
tightly controlled. The ability of an engine management system to
tightly control the droplet size may contribute to the optimization
of the engine operations.
[0032] Generally, certain applications utilizing ultrasonic
atomizers may be placed as closely as possible to the intake valves
to reduce droplet agglomeration. One embodiment includes ultrasonic
atomizers, followed by a large droplet separator apparatus,
followed by an intake valve in close communication. In one
approach, the large droplet separator can act as the water/air/fuel
mixer.
[0033] In other embodiments, additional techniques for droplet
formation are possible such as electrostatic atomization. While
electrostatic atomization is capable of creating fine droplets,
electrostatic atomization may not be desired in certain embodiments
that include a spark ignited engine due to the electrical discharge
that it may generate.
[0034] Another embodiment may include flash atomizers to provide
similar atomization. Flash atomizers create small droplets by
heating pressurized liquid so that a portion boils when released
from the atomizer to a lower pressure. The boiling action breaks an
initial large droplet into smaller droplets. This action may take
place in a continuous atomizer or heated injector (presumably
common rail injector). Flash atomization also enables in-cylinder
injection in a reciprocating internal combustion engine, which can
enhance performance and controllability of the wet compression
process. Flash atomization may also be accomplished by adding a gas
that is highly miscible in the injected coolant at high pressure
but escapes as a vapor at low pressures to avoid heating the
liquid. For, example, carbon dioxide dissolves in water at high
pressures, but causes secondary atomization when released to lower
pressures, even at ambient temperatures.
[0035] Flash atomization may be done by a steady-state atomizer,
port injector, or direct in-cylinder injection (in order of
increasing complexity and control capabilities). For one
embodiment, a common rail injector holds fluid around 200 bar. At
200 bar liquid water can be heated to over 200.degree. C. without
vaporizing. Upon the injector opening, the pressurized hot water is
released to a lower pressure, e.g. 1 bar. At 1 bar, 200.degree. C.
is above the boiling temperature for water. The liquid droplet
atomized from the injector begins to boil, including internal
vaporization. Internal vaporization contributes to a primary
droplet breaking into many smaller droplets. Small secondary
droplets are then available for wet compression applications.
[0036] Following atomization, injection may take place inside the
combustion chamber or outside the combustion chamber. Within the
combustion chamber, liquid can be injected during the intake stroke
or just after the intake valve closes. Both internal injection and
external injection before the intake stroke improves volumetric
efficiency by cooling the intake charge air, thus increasing its
density. Internal injection after the intake valve closes provides
greater cooling for a similar amount of liquid injection due to a
smaller air mass. Internal injection enables injection timing
optimization that minimizes internal surface wetting by injecting
at a rate similar to the vaporization rate. Matching injection and
vaporization rates minimizes the residence time of water droplets
in the power cylinder. While internal injection provides greater
control, injectors outside of the combustion chamber are generally
less expensive.
[0037] It should be appreciated that any liquid may be flash
atomized. In an illustrative embodiment, ethanol, or ethanol/water
mixes, can be injected as the primary fuel, with flash atomization
increasing wet compression, and correspondingly the upper
efficiency limit, as well as improved combustibility since more
fuel is vaporized before combustion. This injection technique can
also enhance engine efficiency with gasoline, though gasoline
provides less cooling since it has a relatively lower enthalpy of
vaporization. Alternatively, inert liquids such as water may be
injected to provide cooling exclusively.
[0038] The source of the liquid coolant may be an issue as much as
the choice of coolant. Some liquid source contamination, such as
carbon particles in condensed exhaust gas vapors, may be benign to
the engine, but may cause significant harm to injectors. Ultrasonic
atomizers usually do not rely on small openings like pressurized
injectors, and so they are less likely to plug due to
contamination. Additionally, ultrasonic atomizers spray anything
carried in the water supply, and so the water supply content should
be considered.
[0039] In other embodiments, wet compression utilizes a source of
engine-safe water. The water source may be met by three exemplary
conditions: stationary primary power such as combined heat and
power systems (CHP), exhaust gas recirculation (EGR), and exhaust
water recovery systems similar to those used in fuel cells. CHP
systems are generally connected to water supplies, and adding
components, such as water purifiers, generally will not
significantly add to the system size. EGR cooling systems provide
for the uncontrolled introduction of water to the engine after
precipitation in the cooler. Alternatively, condensation from EGR
coolers may be collected and finely atomized to enable wet
compression.
[0040] In one approach, cooled EGR water from an exhaust gas
condenser may serve as an adequate liquid source. Alternatively or
additionally, external water may be used with filtering and/or
distilling as desired. Because there is already significant heating
and cooling taking place in engines, integrated distillation
systems may be a cost effective approach to providing clean
water.
[0041] In another embodiment, the droplets removed from the air
stream may be collected and returned to the entrainment system to
attempt to re-introduce them at a reduced size. Droplet recycling
applies in cooled EGR applications, for example, where large water
droplets are present in the air-fuel stream and may provide a
majority of the water for the atomizer, which reduces the need for
external water supplies. Water may also be recycled from the
exhaust gas independent of other exhaust systems such as an EGR
cooler.
[0042] One approach to increasing effectiveness of wet compression
includes removing liquid droplets that are larger than desired.
Droplet separation increases the cycle efficiency by removing
droplets that would otherwise cool the combustion process.
Separation also increases liquid use efficiency by enabling liquid
recycling. For example, a 100 micron diameter droplet that is
captured and recycled can produce 1,000,000-1 micron diameter
droplets which would have 10,000 times the total surface
area--significant for cooling.
[0043] Droplet separation may be done by several processes known in
the art, for example, inertial separation or a screen. Inertial
separation, which uses the difference in mass vs. surface area
between small and large particles, may take place in a cyclonic
separator. Another inertial separator uses barrier plates that the
airflow is directed around. Either a cascading impactor or virtual
impactor may be used for this type of separation. Larger droplets
may find it more difficult to follow the airflow around the barrier
plates and impinge on the surfaces. A screen may provide barriers
of known separation that don't allow larger droplets through. Such
a screen may have wire spacing less than 10 microns. Another
embodiment may utilize air filtration with certain adjustments
relative to other standard intake pathway components. This
embodiment may locate a droplet separator after the intercooler and
throttle.
[0044] In certain implementations, droplet separation may be placed
after the liquid or particle injection into the gas stream to
remove large particles that may cause ill effects when entering the
cylinder of a reciprocating internal combustion engine. Smaller
droplets are allowed to pass through, enabling wet compression to
take place. A majority of larger particles are removed and may be
recycled into smaller droplets and entrained in the airflow again.
Other separator methods may include gravitational or electrostatic
forces to name a few.
[0045] Wet compression that takes place throughout the compression
stroke may over-cool the air/fuel mixture. A hybrid condition
between wet and dry compression may provide optimal efficiency for
a wide variety of compression ratios. A hybrid cycle begins with
wet compression. Wet compression at the beginning of the hybrid
cycle minimizes entropy production during vaporization while
reducing the temperature increase during compression. The
appropriate amount of liquid is injected to force a transition to
dry compression during the compression stroke after the liquid
fully vaporizes. The hybrid cycle enables the pre-ignition
temperature to be as high as possible without knocking. The
elevated temperature addresses the efficiency loss from full wet
compression. When the coolant completely vaporizes during
compression, there is no further cooling during combustion and
expansion, leaving a more optimal isentropic or polytropic index of
compression. The index of compression may be isentropic for systems
behaving as ideal gases or polytropic for conditions when the ideal
is not achieved.
[0046] The hybrid wet and dry compression cycle may deliver an
exemplary knock-free efficiency for compression ratios above the
knock limit for dry compression. The optimal wet compression for a
given pre-ignition temperature limit may be determined. The knock
limited compression ratio may be over 40:1, with over 70%
theoretical efficiency possible. This knock-free compression ratio
is possible due to the cooling effects of wet compression, which
limit the temperature and pressure rise that is likely to otherwise
occur with dry compression.
[0047] In addition to improving efficiency, wet compression enables
greater engine control. The pre-ignition temperature may be
controlled by adjusting the duration of wet compression. The
duration of wet compression may be set by the amount of liquid or
solid coolant that is added to the charge air. With a flash
atomized injector in one embodiment, liquid injection may vary from
cycle to cycle, similar to common rail diesel injectors. The
control of wet compression ratio may enable rapid control of
pre-ignition temperatures and pressures.
[0048] Pre-ignition temperature control provides many of the same
benefits as variable compression ratio engines. As the fuel
quality, air-fuel ratio, or inlet air conditions change, the
knocking characteristics of the engine change. Wet compression may
enable the engine to adapt to these changes on a cycle by cycle
basis. Homogeneous charge compression ignition (HCCI) is one
application that requires control over air/fuel conditions at or
near top dead center. Well controlled wet compression may enable
the engine to adapt to auto-ignition changes due to fuel or charge
air changes. As charge air conditions change in one cycle, the
injector may adjust the amount of liquid injected in the next cycle
to maintain robust HCCI. Well controlled wet compression may
provide the benefits of a variable compression ratio engine, but
with the possibility of controlling and optimizing each engine
cycle and cylinder separately.
[0049] Because the air/fuel mixture is cooled during compression,
the pressure increase may be lower than it would be without
cooling. Although the compression ratio may be relatively high, the
pressure ratio and temperature ratio for the start of compression
relative to the end of compression is lower than the temperature
and pressure ratios for the expansion stroke. This difference in
pressure and temperature ratios makes the inter-cooling by wet
compression operate in a manner similar to miller cycle engines,
but with improved power density.
[0050] By introducing sufficiently small liquid droplets to the
air-flow, the liquid becomes entrained and keeps the charge air
cool during the intake stroke. The introduction of the small
droplets may increase the total volumetric efficiency, and thus
also increase the power density. Although the amount of liquid may
be increased to induce wet compression, small amounts of liquid
will generally induce improved volumetric efficiency. Though
reference is made to liquid introduction, phase change is believed
to be the principle mechanism, thus solids may also be used.
[0051] At low levels of micro-droplet water introduction during the
intake stage in one embodiment, the droplets often vaporize before
reaching the compression stage. Some droplets may keep the intake
air cool as it is heated by the surrounding cylinder walls, piston,
and cylinder head, as well as the remaining exhaust leftover from
the previous cycle. By reducing the charge air temperature, more
air is likely to enter the cylinder, which correspondingly
increases the power density. Intake air cooling can improve
performance of both compression ignition and spark ignition
engines.
[0052] Engines generally require higher compression ratios or more
advanced ignition timing to increase efficiency. Increasing
compression ratio and advancing ignition timing generally increases
NO.sub.x emissions. In another embodiment, wet compression lowers
pre-ignition temperature, therefore lowering peak temperature, and
additionally lowering NO.sub.x emissions while still providing high
compression ratios and ignition timing in a thermodynamically
efficient manner without the propensity to knock. Though this
applies mainly to spark ignition engines, it also reduces NO.sub.x
production in compression ignition engines, even at high
compression ratios and advanced injection timing.
[0053] Although there is a potential to improve knock margin and
reduce NOx production, uncontrolled introduction of liquid to an
Otto or Diesel cycle engine may also increases cycle entropy, thus
decreasing cycle efficiency. Overall system efficiency increases
are made possible by the present application. Wet compression under
optimized conditions may allow advanced ignition timing, higher
brake mean effective pressure (BMEP), lower combustion temperature,
and higher compression ratios, each of which may contribute to
system efficiency.
[0054] Wet compression is capable of reducing pre-combustion
temperature and pressure. These pre-combustion effects may be
beneficial for knock reduction but can be detrimental to
efficiency. Excessive wet compression may lead to significantly
lower pre-combustion pressure, such that the combustion process
provides a smaller peak pressure, and results in lower efficiency.
Wet compression may provide more cooling than pressure reduction,
so if the compression ratio is increased to the knock limit, the
cycle efficiency will improve.
[0055] Engine knock generally limits the maximum boost pressure
available in a reciprocating internal combustion engine. This knock
limit to boost pressure relation may be applied to engines with
stoichiometric air/fuel mixtures. In one embodiment, wet
compression suppresses knock by reducing the pre-ignition
temperature of the air/fuel mixture. This knock suppression enables
higher boost pressures, increasing the power density and BMEP,
which tends to increase system efficiency. In another embodiment,
wet compression differs from water injection because the liquid is
more completely vaporized before combustion, thus enabling an
efficient combustion process and improved cycle efficiency.
[0056] Homogeneous charge compression ignition (HCCI) engines
operate by compressing the air/fuel mixture such that it
auto-ignites near the end of the compression stroke. In such
applications, the system operates to time the auto-ignition
temperature, which if too early tends to cause the engine to knock
heavily and if too late the engine may not fire at all. As the
air/fuel mixture conditions change, the auto-ignition temperature
also changes. Thus changing power output generally includes a
change in the temperature reached at the end of the compression
stroke.
[0057] In yet another embodiment, wet compression may enable
control over the maximum temperature reached during the compression
stroke by providing cooling early during compression. In this
embodiment, a compression ratio is set to provide HCCI during lean
operation. As the air/fuel mixture becomes richer, the
auto-ignition temperature is lowered, causing early ignition.
Adding more fine water droplets can reduce the temperature rise
from compression and delay auto-ignition to the appropriate time.
The logic to change the quantity of water added may be dependant
upon sensors detecting the combustion conditions of the previous
cycle or cycles. In addition to HCCI control, the logic may also
control incipient knock in an engine. When the engine power
requirement is reduced, micro-droplet production may be reduced,
reducing cooling and enabling auto-ignition at the appropriate
time.
[0058] One aspect of wet compression is an inter-cooling effect
during compression. An injected liquid quantity may be adjusted to
have wet compression only at the beginning of the engine cycle with
most of the compression stroke taking place with only gases.
Because wet compression may reduce knock, enable higher boost
pressures, increase compression ratio, advanced spark timing, etc.,
an operating condition may be determined by engine designers after
removing knock limits from their existing optimization
routines.
[0059] Insulating the combustion chamber in a reciprocating
internal combustion engine is known to improve fuel conversion
efficiency by retaining more of the heat in the cylinder during
expansion. Combustion chamber insulation also provides hotter
exhaust gases, which increases the potential efficiency gained by
combined heat and power systems and bottoming cycles such as
turbo-compounding or Rankine cycles to improve total system
efficiency. Conversely, the heat retained by the combustion chamber
insulation after combustion contributes to knock in spark ignition
engines and higher NO.sub.x emissions in both Otto and Diesel cycle
engines. Wet compression may alleviate negative effects of
combustion chamber insulation for both Otto cycle and Diesel cycle
engines.
[0060] Engine insulation has generally been limited to compression
ignition engines due to the knock issues in spark ignition engines.
Research has been done on adiabatic spark ignition engines, but no
viable design has resulted due to the knock limiting aspects. An
embodiment of the present invention enables high compression ratio
and boost for an insulated spark ignition internal combustion
engine.
[0061] Wet compression contributes to the reduction and/or
elimination of the ill effects of combustion chamber insulation by
assisting to cool the combustion chamber gases before compression.
Evaporative cooling by wet compression enables high compression
ratios by reducing the index of compression, which allows lower
temperature rises during compression.
[0062] In one embodiment, cylinder insulation may be more effective
with wet compression due to a larger relative effect. Additionally,
the ill effects of cylinder/piston/head insulation, specifically
increased knock tendency and NOx formation, may be reduced or
eliminated (assuming other mechanisms such as but not limited to a
three way catalyst is used in stoichiometric combustion).
[0063] For one embodiment, wet compression contributes to lowering
the in-cylinder temperature in a reciprocating internal combustion
engine to suppress knock and enabling combustion chamber
insulation. Combustion chamber insulation may be an insulating
coating of the piston, head, or cylinder where the insulating
coating may be made of a ceramic. It also includes creating engine
components such as the piston, head, or cylinder out of insulating
materials. Wet compression may also enable insulation on diesel
engines while maintaining low NO.sub.x production and high
volumetric efficiency.
[0064] Some alternative fuel designs are made more viable by one
embodiment of a system designed for wet compression. When
bio-ethanol is produced under certain conditions, the fuel is often
separated from the water that was used in the biological
processing. Initial separation may take place by distillation;
final water/ethanol separation may take place with rechargeable
desiccants. Final separation adds cost and complexity to the
ethanol production process. Making an engine run on water/ethanol
mixes can reduce the processing requirements for ethanol
production. Utilizing water/ethanol mixes as fuel could reduce the
processing demands, and thus fuel cost, for ethanol. Using current
methods however, water/ethanol is difficult to reliably ignite due
to the high latent heat of vaporization and the need for ethanol to
be in gaseous form to ignite.
[0065] Simultaneously, evaporative cooling and wet compression with
pure water is less efficient due to the surface tension of water
complicating the creation and vaporization of small droplets.
Adding ethanol to water generally reduces the surface tension and
boiling point of the water, simplifying atomization and the
resulting smaller droplets.
[0066] One embodiment uses the high latent heat of ethanol/water
mixes to provide the benefits of evaporative cooling and wet
compression by finely atomizing the water/ethanol mix. This fine
atomization (<5 .mu.m diameter) is made easier than with just
water partly due to the surface tension reducing qualities of
ethanol in water. The benefits of evaporative cooling and wet
compression may enable higher compression ratios and reduced engine
cooling (via insulated combustion chamber). The high compression
ratio and insulated engine contribute to improving efficiency and
power density while reducing cold-starting problems generally
associated with ethanol/water mixes. In one embodiment of a direct
injection engine, high compression ratio and insulated engine
design may be used to provide open-throttle power management,
further increasing efficiency.
[0067] In one embodiment, un-throttled power output can be
controlled by timing the ethanol/water injection in the case of
direct injection engines. Injection during the intake stroke may
improve the evaporative cooling effect during intake, and
correspondingly increase the engine's volumetric efficiency.
Injection after the intake valve closes generally does not provide
evaporative cooling during intake, thus a reduced amount of air may
enter the power cylinder. Evaporative cooling and wet compression
effects may take place during compression to contribute to the high
compression ratio and efficiency.
[0068] Increasing the compression ratio too dramatically may cause
catastrophic failure upon disruption of the liquid delivery
system--having the potential to result in excessive knock. Other
system optimizations may take place which would not make water
disruption catastrophic.
[0069] In one embodiment, small amounts of water introduced to the
intake air can benefit the engine in ways that are not completely
dependant upon the liquid delivery system. Wet compression allows:
ignition timing advances, higher knock-free boosting (reducing
friction effects on efficiency), and/or reduced combustion
temperatures (improving NOx and reducing heat transfer to the
engine wall). These effects are present when, in one embodiment,
re-optimizing an engine utilizes wet compression but does not
catastrophically fail without it. The system may be designed such
that if the water system fails, the engine may run sub-optimally
with turbo-boost reductions and delayed ignition timing, but may
not catastrophically fail.
[0070] FIG. 1 depicts a system 10 of one embodiment with an engine
12 which is of the reciprocating piston type having one or more
reciprocating pistons C. In one form, engine 12 is of the four
stroke diesel-fueled type with compression ignition and fuel
injection. In other embodiments, engine 12 can be of a
spark-ignited type, the two-stroke type, a rotary type such as a
wankel engine, and/or may not utilize any form of fuel injection,
to name just a few alternative possibilities. Furthermore, other
embodiments may be differently fueled, such as by gasoline,
ethanol, hydrogen, natural gas, propane, other gaseous fuels,
and/or a hybrid combination of fuel types--just to mention some
possibilities. It is also contemplated that system 10 may, as an
alternative to being used to provide power to mobile applications
such as vehicles, provide power to stationary applications, such as
electrical power generators, pumps, and the like. On such
implementation is depicted as stationary system 10a, and more
specifically depicted with electric power generator 12a being
driven by engine 12--it being understood that both other stationary
and mobile applications (not depicted) are also contemplated to be
within the scope of the present application. In addition, system 10
may be used in hybrid applications that include one or more power
sources in addition to engine 12, such as batteries, fuel cells--to
name a few.
[0071] Engine 12 includes an air intake stream 14. Air intake
stream 14 is in fluid communication with a liquid atomizer 18.
Liquid atomizer 18 may be an ultrasonic atomizer, flash atomizer,
electrostatic atomizer or other suitable type known to one skilled
in the art. As air enters air intake stream 14, liquid atomizer 18
provides liquid droplets to the air. As the air with entrained
liquid droplets continues through the air intake stream 14 of this
embodiment, the liquid droplets are separated based on size by
flowing through a liquid droplet separator 16. Some embodiments may
not include a separator as shown in FIG. 1 or separator 16 may be
configured or positioned to be more integrated with engine 12 or
atomizer 18. Liquid droplet separator 16 may be an inertial,
gravitational or screen based separator. An inertial separator may
be cyclonic or transverse flow through parallel plates. After
passing through liquid droplet separator 16, the air with entrained
liquid droplets enters engine 12 during an intake cycle.
[0072] A controller 20 is connected to and communicates with an
atomizer control signal pathway 28 and various devices of engine 12
through a set of engine control signal pathways 26. Typically,
controller 20 may be included in a standard type of Engine Control
Module (ECM), including one or more types of memory 22. Controller
20 can be an electronic circuit comprised of one or more
components, including digital circuitry, analog circuitry, or both.
Controller 20 may be a software and/or firmware programmable type;
a hardwired, dedicated state machine; or a combination of
these.
[0073] In one embodiment, controller 20 is a programmable
microcontroller solid-state integrated circuit that integrally
includes one or more processing units 24 and memory 22. Memory 22
may be comprised of one or more components and may be of any
volatile or nonvolatile type, including the solid state variety,
the optical media variety, the magnetic variety, a combination of
these, or such different arrangement as would occur to those
skilled in the art. Further, while only one processing unit 24 is
specifically shown, more than one such unit may be included. When
multiple processing units 24 are present, controller 20 may be
arranged to distribute processing among such units, and/or to
provide for parallel or pipelined processing if desired. Controller
20 functions in accordance with operating logic defined by
programming, hardware, or a combination of these.
[0074] In one form, memory 22 stores programming instructions
executed by processing unit 24 of controller 20 to embody at least
a portion of this operating logic. Alternatively or additionally,
memory 22 stores data that is manipulated by the operating logic of
controller 20. Controller 20 may include signal conditioners,
signal format converters (such as analog-to-digital and
digital-to-analog converters), limiters, clamps, filters, and the
like as needed to perform various control and regulation operations
described in the present application. Controller 20 receives
various inputs and generates various outputs to perform various
operations as described hereinafter in accordance with its
operating logic.
[0075] FIG. 2 illustrates a further embodiment of a system 10 with
an engine 12 having one or more reciprocating pistons C positioned
in a cylinder 13 and an air stream 14. For each cylinder 13 of
engine 12, a liquid atomizer 18 and a liquid droplet separator 16
are positioned in close proximity to cylinder 13. One embodiment
allows for injection of liquid droplets into air stream 14 just
before entering cylinder 13. Another embodiment allows for direct
injection of liquid droplets atomized by liquid atomizer 18 and
separated by liquid droplet separator 16 into cylinder 13. In a
further embodiment, each liquid atomizer 18 alternatively
communicates directly with cylinder 13 without liquid droplet
separator 16. Each liquid atomizer 18 is in communication via lines
28 with controller 20 to allow optimization of engine operating
parameters via lines 26 on an individual basis based on wet
compression performance in each cylinder 13.
[0076] FIG. 3 illustrates yet another embodiment where a system 10
includes an engine 12 with reciprocating pistons C similar to the
embodiment shown in FIG. 1. Engine 12 includes an air intake stream
14 and an exhaust air stream 32. Air intake stream 14 is in fluid
communication with a liquid atomizer 18 and a liquid droplet
separator 16. Exhaust air stream 32 is in fluid communication with
an EGR system 30. A water source 40 is in communication with EGR
system 30 to receive water via line 42 from recirculating exhaust
gases. Water source 40 is in further communication with liquid
atomizer 18 to supply water via line 44 to liquid atomizer 18 for
droplet formation. Water source 40 is also in communication with
liquid droplet separator 16 to receive water via line 46 from large
droplets separated out of the air stream.
[0077] The index of compression whether isentropic or polytropic is
adjusted with wet compression resulting from the selective and
controlled injection of small water droplets in the air intake of a
reciprocating engine. In one embodiment, controller 20 may be
responsible for collecting engine operating parameters and
establishing the related engine operation limits to induce
efficient and optimized compression and combustion conditions while
limiting engine knock and NOx emissions.
[0078] Various engine operating parameters contribute to engine
operating limits. Most reciprocating engines monitor fuel quality,
air/fuel ratio and intake air temperature as each of these
parameters may be a factor in engine performance. Further
parameters such as charge air temperature, charge air density and
peak pressure can be used to determine engine operating limits or
used as an engine operating limit directly. Pre-ignition
temperature can be used as an engine operating limit when
controlling knock conditions. A knock detector may also provide
readings to be used as an engine operating limit. Additionally, a
NO.sub.x detector may provide readings for an engine operating
limit.
[0079] Engine operating limits are determined to optimize engine
performance including eliminating engine knock, increasing
volumetric efficiency and increasing over all peak performance and
efficiency. A wet compression level can be calculated that allows
control over the engine operating parameters for each cycle of the
piston and cylinder in the engine. One embodiment would include a
wet compression injection schedule that can be modified on a cycle
by cycle basis.
[0080] Controller 20 may adjust additional engine operating
parameters as the logic performs a re-optimization module where the
engine conditions are based on the resulting performance with wet
compression. In FIG. 4, an embodiment is shown with apparatus 400
which includes controller 420 with various components illustrated
as representative modules, inputs and outputs.
[0081] Engine operating limit module 405 is structure to determine
operating conditions in a number of modules which may be controlled
when a wet compression level is applied in response to the engine
operating limit.
[0082] One embodiment is shown as Module 430 which is a
pre-ignition condition module 430 structured to determine engine
operating limits including a desired temperature change based on a
detected pre-ignition temperature 432 and ignition parameters 434
selected for optimized engine performance. The temperature change
is used by wet compression module 410 to determine a level of wet
compression capable of accomplishing the temperature change.
[0083] Another embodiment is shown as Module 440 which is an
adaptive performance module structured to determine engine
operating limits to allow dynamic response to changes in engine
conditions such as, but not limited to, fuel quality 442, air/fuel
ratio 444 and intake or charge air temperature 446. The engine
operating limits are used by wet compression module 410 to
determine a level of wet compression capable of accomplishing the
engine operating change.
[0084] Yet another embodiment is shown as Module 450 which is an
HCCI module 450 structured to determine engine operating limits for
a homogeneous charge compression ignition engine including an
auto-ignition timing based on auto-ignition conditions 452 of the
last cycle or a function of some number of previous cycles selected
to ensure optimal ignition sequencing with piston position 454. The
engine operating limits are used by wet compression module 410 to
determine a level of wet compression capable of accomplishing the
auto-ignition timing.
[0085] Still another embodiment is shown as Module 460 which is a
knock reduction module 460 structured to determine engine operating
limits based on knock detection readings 465. The engine operating
limits are used by wet compression module 410 to determine a level
of wet compression capable of accomplishing the knock
reduction.
[0086] Module 410 is a wet compression level module 410 structured
to determine a level of wet compression to achieve the engine
operating limits determined in module 405. One specific embodiment
may include determining a wet compression level incorporating a
hybrid compression schedule 415.
[0087] Module 470 is an injection schedule module 410 structured to
determined an injection amount 472, an injection timing 474, and an
injection location 476 to provide the determined wet compression
level from module 410.
[0088] A further embodiment is shown as Module 480 which is a
reoptimization module 480 structured to determine engine
performance parameters that may be re-optimized following the
reduction of knock limits with wet compression. Some of the
performance parameters may include increased boost pressure 482,
increased compression ratio 484, and advanced spark timing 486, to
name a few.
[0089] Many further embodiments of the present application are
envisioned. Among the inventions desired to be protected are:
[0090] One embodiment includes a reciprocating internal combustion
engine with at least one piston and cylinder set and an intake
stream; at least one liquid atomizer in fluid communication with
the intake stream operable to provide a plurality of liquid
droplets with a diameter range less than 10 .mu.m to the intake
stream; and a controller wherein the controller is operable to
adjust an index of compression for the engine performed on an
engine cycle by engine cycle basis by calculating a wet compression
level in response to an engine operating limit such as a
pre-ignition temperature threshold which may be determined in
response to a set of current engine knock detector readings; and
adjusting the at least one liquid atomizer in response to the wet
compression level by selecting a liquid injection amount; and
selecting a liquid injection timing.
[0091] A feature of the present embodiment includes at least one
liquid droplet separator in fluid communication with the intake
stream positioned upstream from the at least one liquid atomizer
and downstream from the engine. Another feature includes a diameter
range of less than 2.7 .mu.m. The wet compression level may include
a feature where an amount of liquid is provided for a transition to
a dry compression state after the amount of injected liquid fully
evaporates.
[0092] A further feature may include a plurality of liquid droplet
injectors, a plurality of liquid droplet separators and a plurality
of piston and cylinder sets where the liquid droplet injectors and
the liquid droplet separators are provided for each piston and
cylinder set and where each liquid droplet injector and each liquid
droplet separator are in close proximity to each piston and
cylinder set. Yet a further feature may include the engine
operating limit being determined in response to a set of
auto-ignition conditions and where calculating the wet compression
level is based on a set of engine cycle conditions changing with
each engine cycle.
[0093] Another embodiment includes operating a reciprocating
internal combustion engine with at least one piston and cylinder
set and an air intake stream; atomizing a plurality of liquid
droplets with a diameter less than 5 .mu.m; providing the plurality
of liquid droplets to the air intake stream; separating the
plurality of liquid droplets; providing the plurality of liquid
droplets in the air intake stream to the engine; and optimizing an
engine operating limit based on the plurality of liquid droplets in
the air intake stream including calculating a wet compression level
in response to the engine operating limit; and adjusting a liquid
atomizer in response to the wet compression level by selecting a
liquid injection amount; and selecting a liquid injection timing.
Providing the plurality of liquid droplets in the air intake stream
to the engine may include injecting the plurality of liquid
droplets into the air intake stream according to a liquid droplet
injector sequence.
[0094] Yet another embodiment includes a reciprocating internal
combustion engine with at least one piston and cylinder set and an
intake stream; at least one atomizer means for atomizing a coolant
in fluid communication with the intake stream operable to provide a
plurality of coolant particles with a diameter range less than 5
.mu.m to the intake stream; and a control means operable to adjust
an isentropic index of compression for the engine by a means for
detecting a knock level of the engine; a means for calculating a
wet compression level in response to the knock level of the engine
exceeding a knock threshold; and a means for adjusting a coolant
atomization control schedule for the at least one atomizer means in
response to the wet compression level. Calculating the wet
compression level may include determining an amount of coolant
particles when the coolant particles are provided on a continuous
basis; and determining a duration for providing coolant particles
when the at least one means for atomizing a coolant is capable of
providing a set amount of coolant particles to the intake
stream.
[0095] A further inventive apparatus includes: a reciprocating
internal combustion engine with at least one piston and cylinder
set and an intake stream; at least one liquid atomizer in fluid
communication with the intake stream operable to provide a
plurality of liquid droplets with a diameter range less than 10
.mu.m to the intake stream; and a controller wherein the controller
is operable to adjust an index of compression for the engine by
calculating a wet compression level in response to an engine
operating limit; and adjusting the at least one liquid atomizer in
response to the wet compression level.
[0096] Features of the inventive apparatus include at least one
liquid droplet separator in fluid communication with the intake
stream positioned downstream from the at least one liquid atomizer
and upstream from the engine; a diameter range of less than 5 .mu.m
or less than 2.7 .mu.m; the plurality of liquid droplets including
a fuel/water mix; adjusting the at least one liquid atomizer
further including: selecting a liquid injection location, selecting
a liquid injection amount, and selecting a liquid injection timing;
and a closed system water source in fluid communication with the at
least one liquid atomizer.
[0097] Further features of the inventive apparatus may include the
engine operating limit having a pre-ignition temperature threshold
where the pre-ignition temperature threshold may be determined in
response to a set of engine knock detector readings and/or where
the engine operating limit is determined in response to a set of
auto-ignition conditions and where calculating the wet compression
level is based on a set of engine cycle conditions changing with
each engine cycle. The wet compression level may include an amount
of liquid determined to provide a transition to a dry compression
state after the amount of liquid fully evaporates. The inventive
apparatus may further include a plurality of liquid droplet
injectors, a plurality of liquid droplet separators and a plurality
of piston and cylinder sets where the liquid droplet injectors and
the liquid droplet separators may be provided for each piston and
cylinder set and where each liquid droplet injector and each liquid
droplet separator may be in close proximity to each piston and
cylinder set. Adjusting the index of compression may be performed
on an engine cycle by engine cycle basis. The liquid atomizer may
further include a process selected from the group consisting of
ultrasonic atomization, electrostatic atomization, flash
atomization and combinations thereof.
[0098] A further embodiment is a method including: operating a
reciprocating internal combustion engine with at least one piston
and cylinder set and an air intake stream; atomizing a plurality of
liquid droplets with a diameter less than 5 .mu.m; providing the
plurality of liquid droplets to the air intake stream; separating
the plurality of liquid droplets; providing the plurality of liquid
droplets in the air intake stream to the engine; and optimizing an
engine operating limit based on the plurality of liquid droplets in
the air intake stream including calculating a wet compression level
in response to the engine operating limit; and adjusting a liquid
atomizer in response to the wet compression level by selecting a
liquid injection amount and selecting a liquid injection
timing.
[0099] Further features of this method include providing the
plurality of liquid droplets in the air intake stream to the engine
by injecting the plurality of liquid droplets into the air intake
stream according to a liquid droplet injector sequence and the
liquid droplets having a diameter range of less than 2.7 .mu.m.
[0100] Yet a further inventive apparatus includes: a reciprocating
internal combustion engine with at least one piston and cylinder
set and an intake stream; at least one atomizer means for atomizing
a coolant in fluid communication with the intake stream operable to
provide a plurality of coolant particles with a diameter range less
than 5 .mu.m to the intake stream; and a control means operable to
adjust an isentropic index of compression for the engine by: a
means for detecting a knock level of the engine; a means for
calculating a wet compression level in response to the knock level
of the engine exceeding a knock threshold; and a means for
adjusting a coolant atomization control schedule for the at least
one atomizer means in response to the wet compression level.
Features of this further inventive apparatus include calculating
the wet compression level by determining an amount of coolant
particles when the coolant particles are provided on a continuous
basis and determining a duration for providing coolant particles
when the at least one means for atomizing a coolant is capable of
providing a set amount of coolant particles to the intake stream;
and where the at least one piston and cylinder set at least
partially include insulating material.
[0101] Any theory, mechanism of operation, proof, or finding stated
herein is meant to further enhance understanding of the present
invention and is not intended to make the present invention in any
way dependent upon such theory, mechanism of operation, proof, or
finding. It should be understood that while the use of the word
preferable, preferably or preferred in the description above
indicates that the feature so described may be more desirable, it
nonetheless may not be necessary and embodiments lacking the same
may be contemplated as within the scope of the invention, that
scope being defined by the claims that follow. In reading the
claims it is intended that when words such as "a," "an," "at least
one," "at least a portion" are used there is no intention to limit
the claim to only one item unless specifically stated to the
contrary in the claim. Further, when the language "at least a
portion" and/or "a portion" is used the item may include a portion
and/or the entire item unless specifically stated to the contrary.
While the invention has been illustrated and described in detail in
the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the selected embodiments have been shown
and described and that all changes, modifications and equivalents
that come within the spirit of the invention as defined herein or
claims that follow are desired to be protected.
* * * * *